Champion 100520 Operator'S Manual Download

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100520 - 8750W PORTABLE INVERTER GENERATOR

TABLE Of CONTENTS

Introduction

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Safety Definitions

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Important Safety Instructions

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Fuel Safety

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Safety Labels

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Safety Symbols

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Operation Symbols

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Quick Start Label Symbols

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Controls and features

.................................

Generator

.........................................................

Control Panel

.....................................................

Intelligauge

.......................................................

FCC Statement

...................................................

Assembly

.....................................................

Unpacking

........................................................

Remove Shipping Support Brackets

.............................

Install the Wheel Kit

..............................................

Connect the Battery

..............................................

Add Engine Oil

....................................................

Add Fuel

..........................................................

Grounding

........................................................

Operation

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Generator Location

...............................................

Surge Protection

.................................................

Starting the Engine

...............................................

Connecting Electrical Loads

.....................................

Do Not Overload Generator

......................................

GFCI

...............................................................

Eco (Economy) Mode

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12V DC Automotive Style Outlet

.................................

Stopping the Engine

..............................................

Operation at High Altitude

.......................................

Moving the Generator

............................................

Maintenance

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Cleaning the Generator

..........................................

Changing the Engine Oil

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Cleaning and Adjusting the Spark Plug

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Cleaning the Air Filter

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Cleaning the Spark Arrestor

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Adjusting the Governor

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Maintenance Schedule

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Storage

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Short Term Storage (up to 30 days)

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Mid Term Storage (30 days – 1 year)

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Long Term Storage (over 1 year)

................................

Removing from Storage

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Specifications

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Generator Specifications

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Engine Specifications

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Oil Specifications

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Fuel Specifications

...............................................

Temperature Specifications

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Parts Diagram

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Parts List

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Engine Parts Diagram

............................................

Engine Parts List

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Wiring Diagram

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Troubleshooting

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Warranty*

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Warranty Qualifications

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Repair/Replacement Warranty

...................................

Do Not Return The Unit To The Place Of Purchase

.............

Warranty Exclusions

.............................................

Other Exclusions

.................................................

Limits of Implied Warranty and Consequential Damage

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Contact Information

..............................................

Summary of Contents for 100520

Page 1: ...before operating the product Failure to do so could result in serious injury This manual should remain with the product Specifications descriptions and illustrations in this manual are as accurate as known at the time of publication but are subject to change without notice This product is rated in accordance with PGMA Portable Generator Manufacturers Association standard ANSI PGMA G300 Safety and ...

Page 2: ...eration at High Altitude 23 Moving the Generator 23 Maintenance 24 Cleaning the Generator 24 Changing the Engine Oil 24 Cleaning and Adjusting the Spark Plug 24 Cleaning the Air Filter 25 Cleaning the Spark Arrestor 25 Adjusting the Governor 25 Maintenance Schedule 26 Storage 26 Short Term Storage up to 30 days 26 Mid Term Storage 30 days 1 year 26 Long Term Storage over 1 year 27 Removing from St...

Page 3: ...always exercise common sense and always err on the side of caution when operating the product to ensure no accident property damage or injury occurs We want you to continue to use and be satisfied with your CPE product for years to come When contacting CPE about parts and or service you will need to supply the complete model and serial numbers of your product Transcribe the information found on yo...

Page 4: ...tating parts can entangle hands feet hair clothing and or accessories Traumatic amputation or severe laceration can result Keep hands and feet away from rotating parts Tie up long hair and remove jewelry DO NOT wear loose fitting clothing dangling drawstrings or items that could become caught DANGER Generator produces powerful voltage DO NOT touch bare wires or receptacles DO NOT use electrical co...

Page 5: ...could result When starting engine pull the starter cord slowly until resistance is felt and then pull rapidly to avoid kickback DO NOT start or stop the engine with electrical devices plugged in and turned on CAUTION Exceeding the generator s running capacity can damage the generator and or electrical devices connected to it DO NOT overload the generator DO NOT tamper with the governed speed DO NO...

Page 6: ...e from the gasoline tank Only fill or drain gasoline outdoors in a well ventilated area DO NOT pump gasoline directly into the generator at the gas station Always use an approved fuel container to transfer the gasoline to the generator DO NOT overfill the gasoline tank Always keep gasoline away from sparks open flames pilot lights heat and other sources of ignition When starting the generator DO N...

Page 7: ...r B 1110 L OP A UNLEADED FUEL ONLY Minimum octane rating of 85 Maximum 10 ethanol GASOLINA REGULAR SOLAMENTE 85 octanos como mínimo Máximo de etanol de 10 ESSENCE SANS PLOMB SEULEMENT Indice d octane minimal de 85 Maximum 10 d éthanol K 109 Colors LPN 1110 L OP Rev A Size 46 x 46 mm Artwork Notes 3mm corner radius 2mm safe margin white to be printed shown in 50 process magenta Revision Changes Thi...

Page 8: ... before operation Electric Shock Failure to use in dry conditions and to observe safe practices can result in electric shock Improper connections to a building can allow current to backfeed into utility lines creating an electrocution hazard A transfer switch must be used when connecting to a building Fire Explosion Fuel and its vapors are extremely flammable and explosive Fire or explosion can ca...

Page 9: ...ow you to more safely operate the product SYMBOL MEANING START ON STOP or OFF Choke Pull choke knob to CHOKE position Run Push choke knob to RUN position ECO Economy Mode Switch AC Reset Output OK Overload Low Oil Circuit Breaker Reset Push Neutral Bonded to Frame Neutral circuit IS electrically connected to the frame ground of the generator SYMBOL MEANING 12V Direct Current Locking Receptacle Gro...

Page 10: ...parties without the explicit consent of Champion Power Equipment K 376 186 152 CG1 2945 Colors Starting the Engine DANGER Move generator outside and far away from windows doors and intake ventilation covers 1 Check oil level Recommended oil is 10W 30 2 Check gasoline level When adding gasoline use a minimum octane rating of 85 and an ethanol content of 10 or less by volume 3 Turn the fuel valve to...

Page 11: ...t 3 Fuel Valve Used to turn fuel supply on and off to engine 4 Air Filter Protects the engine by filtering dust and debris from the intake air 5 Recoil Starter Used to manually start the engine 6 Never Flat Wheels 8 in 20 3 cm 7 Battery Provides 12V DC power the starting system 8 Oil Fill Cap Dipstick Used to check and fill oil level 9 Ground Terminal Consult an electrician for local grounding reg...

Page 12: ...gize receptacles after overload fault 9 Circuit Breakers Push Reset Protects the generator against electrical overloads RECEPTACLES A z 12V DC 8 Amp Automotive May be used to supply electrical power for operation of 12 Volt DC 8 Amp electrical loads B C 4 120V AC 20A GFCI NEMA 5 20R May be used to supply electrical power for operation of 120 Volt AC 20 Amp single phase 60 Hz electrical loads C Y 1...

Page 13: ...in hertz Example 60 0 hertz Run Time R Run time of the generator for the current session Example 6 hours Total Run Time Total run time of the generator since first operation Example 16 hours Intelligauge Four mode digital meter for displaying voltage frequency hertz run time and total run time The LCD displays each mode by pressing the button below the display MODE BUTTON ...

Page 14: ...ed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by o...

Page 15: ...to the generator NOTICE DO NOT attempt to run generator without first removing the shipping support brackets Damage to the generator as a result of not removing the brackets will void the warranty 1 BEFORE filling the engine with oil or gasoline tip the generator onto it s recoil end Tip onto the flattened cardboard box the generator came in or other protective surface so as to not scratch the fra...

Page 16: ...of failing to follow these instructions will void your warranty NOTICE The generator rotor has a sealed pre lubricated ball bearing that requires no additional lubrication for the life of the bearing NOTICE The recommended oil type for typical use is 10W 30 automotive oil If running generator in extreme temperatures refer to the following chart for recommended oil type 20 0 20 40 60 Ambient temper...

Page 17: ...s Add Fuel Use clean fresh regular unleaded gasoline with a minimum octane rating of 85 and an ethanol content of 10 or less by volume y b c DO NOT mix oil with gasoline 1 Remove the gasoline cap 2 Slowly add gasoline to the tank Tank is full when gasoline reaches the MAX fill line DO NOT OVERFILL Gasoline can expand after filling A minimum of in 6 4 mm of space left in the tank is required for ga...

Page 18: ...ection will not function if the receptacle ground pin is not functional Neutral Bonded to Frame Neutral circuit IS electrically connected to the frame ground of the generator The generator system ground connects lower frame cross member below the alternator The system ground is connected to the AC neutral wire See your model s control panel for specified type of grounding OPERATION Generator Locat...

Page 19: ...ppressors come in single or multi outlet styles They re designed to protect against virtually all short duration voltage fluctuations Starting the Engine 1 Make certain the generator is on a flat level surface 2 Disconnect all electrical loads from the generator Never start or stop the generator manually with electrical devices plugged in or turned on 3 Turn the gasoline fuel valve to the ON posit...

Page 20: ...the RUN position for 3 more pulls of the recoil starter Too much choke leads to spark plug fouling engine flooding due to lack of incoming air This will cause the engine not to start NOTICE For gas starting in cold ambient temperature 59 F 15 C the choke must be in 100 of CHOKE position for recoil start procedures Do not over choke As soon as engine starts press the choke button to the RUN positio...

Page 21: ...e life of your generator and attached devices follow these steps to add electrical load 1 Start the generator with no electrical load attached 2 Allow the engine to run for several minutes to get up to temperature 3 Plug in and turn on the first item It is best to attach the item with the largest load first 4 Allow the engine to stabilize 5 Plug in and turn on the next item 6 Allow the engine to s...

Page 22: ...he generator 3 Connect the red battery charger lead to the red battery terminal 4 Connect the black battery charger lead to the black battery terminal 5 Start the generator Important The 12V DC outlet is ONLY to be used with the supplied 12V DC battery charging cable The 12V DC output is unregulated and will damage other 12V DC products When using the 12V DC outlet turn the Economy mode switch to ...

Page 23: ...is listed in the following table In order to select the correct high altitude main jet it is necessary to identify the carburetor model For this purpose a code is stamped on the side of the carburetor Select the correct high altitude jet part number corresponding to the carburetor code found on your particular carburetor Carb Code High Alt Jet Part Number Min Altitude 16100 Z980210 16161 Z320410 3...

Page 24: ...r surfaces of the generator 2 Use a soft bristle brush to remove dirt and oil 3 Use an air compressor 25 PSI to clear dirt and debris from the generator 4 Inspect all air vents and cooling slots to ensure that they are clean and unobstructed To prevent accidental starting remove and ground the spark plug wire before performing any service Changing the Engine Oil Change oil when the engine is warm ...

Page 25: ...ark arrestor to the muffler 3 Remove the spark arrestor screen 4 Carefully remove the carbon deposits from the spark arrestor screen with a wire brush See your model s parts list for specified type of spark arrestor 5 Replace the spark arrestor if it is damaged 6 Position the spark arrestor on the muffler and attach with the screws removed in step 2 CAUTION Failure to clean the spark arrestor will...

Page 26: ...ged or appears damaged DO NOT overfill the gasoline tank Always keep fuel away from sparks open flames pilot lights heat and other sources of ignition DO NOT light or smoke cigarettes Short Term Storage up to 30 days Gasoline may gum up and clog the carburetor if the generator is not run or carburetor drained within 4 weeks 1 Be sure all appliances are disconnected from the generator 2 Start the g...

Page 27: ...ose if necessary under the carburetor drain bolt to avoid spillage 3 When gasoline stops flowing from the carburetor replace and tighten the carburetor drain bolt and be sure to properly dispose of the drained gasoline according to local regulations or guidelines 4 Turn the fuel valve to the OFF position 5 Follow steps 8 11 according to Mid Term Storage Removing from Storage If the generator has b...

Page 28: ...Ambient temperature Recommended Engine Oil Type 80 100 120 28 9 F C 17 8 6 7 4 4 15 6 26 7 37 8 48 9 10W 30 5W 30 Synthetic 10W 40 5W 30 NOTICE Temperature will affect engine oil and engine performance Change the type of engine oil used based on the temperature to suit the engine needs Fuel Specifications Use unleaded gasoline with a minimum octane rating of 85 and an ethanol content of 10 or less...

Page 29: ...30 31 32 33 33 33 33 38 39 40 41 42 44 45 46 46 47 47 48 49 50 51 51 52 53 54 55 56 57 58 59 60 61 62 63 63 67 67 68 68 69 69 70 75 72 76 76 76 76 76 76 73 73 73 73 74 74 74 74 64 64 64 29 37 29 29 65 65 5 5 5 5 34 34 36 36 36 36 43 6 6 6 7 35 35 35 35 80 81 82 83 83 84 84 85 86 87 88 88 89 90 91 92 93 94 77 78 79 95 96 97 96 96 66 99 99 99 99 98 ...

Page 30: ...l Unit 1 29 90001 0612 03 Flange Bolt M6 x 12 Black Zinc 3 30 17003 Y290110 0000 Air Cleaner Support 1 31 51002 Y9X0310 H700 Dead Plate 1 Engine 1 32 51002 Y9X0210 H700 Dead Plate 2 Engine 1 Part Number Description Qty 33 51005HY9X0310 0000 Vibration Mount Frame 4 34 90306 1000 31 Flange Nut M10 x 1 25 Blue White Zinc 8 35 90002 1040 01 Flange Bolt M10 x 1 25 x 40 White Zinc 4 36 90305 0800 31 Fla...

Page 31: ...00 USB Adapter 5V 2 4A 1 79 93041 YBE0110 0000 Battery Charger Cables 1 80 35160 Y210110 0000 Switch 16A 250V 1 81 16080 YB30110 0000 Choke Cable Assembly 1 82 35632 Y9X0310 0000 Intelligauge VFT 3 1 83 35614 Y9X0110 0000 GFCI 5 20R Receptacle 2 84 35654 YBE0110 0000 Receptacle Cover GFCI 5 20R 2 85 35614 Y090110 0000 L14 30R Receptacle 125V 250V 30A 1 86 35654 YBE0210 0000 Receptacle Cover L14 30...

Page 32: ...6 17 18 20 21 22 16 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 41 42 43 44 44 45 46 46 47 48 49 50 51 52 53 54 55 56 57 57 58 59 60 61 62 62 63 64 65 66 67 67 68 69 70 71 72 73 74 75 76 77 78 79 79 79 79 79 79 80 81 82 83 85 84 86 87 88 89 90 91 92 93 7 7 8 6 6 26 27 36 37 38 35 34 33 30 31 53 94 95 96 97 19 19 ...

Page 33: ... Inlet Valve 1 31 12121 Z190110 0099 Exhaust valve 1 32 12110 Z190110 0099 Valve set 1 33 12101 Z080110 0000 Seal Guide 1 Part Number Description Qty 34 12105 Z080110 0000 Valve Spring Seat 2 35 12103 Z080110 0000 Valve Spring 2 36 12112 Z080110 0000 Valve Spring Retainer Inlet Valve 1 37 12107 Z080110 0000 Valve Spring Retainer Exhaust valve 1 38 12104 Z080110 0000 Rotator Valve 1 39 14200 Z19051...

Page 34: ...er Body Shroud Blue White Zinc 1 81 19305 Z980120 0000 Cylinder Body Shroud 2 1 82 90684 Z030120 0000 Clip 100 mm 1 83 13501 Z080110 0000 Flywheel Nut M6 x 1 5 Blue White Zinc 1 84 28002 Z980110 0000 Starter Pulley Blue White Zinc 1 85 28020 Z150120 0000 Starter Pulley Base 1 86 19352 Z980110 0000 Impeller 1 87 90007 0665 A1 Hexagon Flange Bolt M6 x 65 Blue White Zinc 3 88 30110 Y9X0110 0000 Rotor...

Page 35: ...COM1 B COM17 B COM14 A Gr COM1 A Gr COM17 A COM15 B COM15 A OUTPUT OVERLOAD LOW OIL BL Y Gr G BL Bu W R Y G O BL Y Gr G BL Bu W R Y G O Y G COM9 A COM9 B COM6 A W Gr BL R Bu hang in the air THROTTLE SWITCH BL W Bu R Gr BL RESET BL R Bu 6A 125V 0 5A 250V hang in the air BL BL W Gr R IGNITOR THIS CIRCUIT DIAGRAM IS ONLY FOR REFERENCE IF ANY CHANGE THERE WILL BE WITHOUT NOTICE O G Y Bu ENG SWITCH FUE...

Page 36: ...ating Generator is overloaded Review load and adjust See Connecting Electrical Loads Dirty air filter Clean or replace air filter Choke in wrong position Move choke until it stops under RUN position or push in completely Engine is running but no AC output Poor cord connection Check all connections Circuit breaker is open Reset circuit breaker Loose wiring Inspect and tighten wiring connections GFC...

Page 37: ...y to any electrical component Normal maintenance is not covered by this warranty and is not required to be performed at a facility or by a person authorized by CPE Other Exclusions This warranty excludes Cosmetic defects such as paint decals etc Wear items such as filter elements o rings etc Accessory parts such as starting batteries and storage covers Failures due to acts of God and other force m...

Page 38: ...e condition exits CPE will repair your small off road engine SORE and equipment at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This Emissions Control System is warranted for two years If any emissions related part on your small off road engine SORE and equipment is defective the part will be repaired or replaced by CPE OWNER WARRANTY RESPONSIBILITIES As the ...

Page 39: ...l shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by CPE according to Subsection d below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for a time not less than the remainder of the ECS Warranty Peri...

Page 40: ... Mounting Brackets Carburetor Purge Port Connector TO OBTAIN WARRANTY SERVICE You must take your CPE engine or the product on which it is installed along with your warranty registration card or other proof of original purchase date at your expense to any Champion Power Equipment dealer who is authorized by Champion Power Equipment Inc to sell and service that CPE product during his normal business...

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